Systems and methods for packaging and transporting bulk materials

ABSTRACT

Apparatus, systems, and methods for housing a bulk material within a flexible container are described herein. In some embodiments, a method includes maintaining a flexible container in an expanded configuration to define an interior volume. A bulk material is conveyed into the interior volume of the expanded flexible container. The flexible container is then moved from the expanded configuration to a collapsed configuration, such that movement of the bulk material within the interior volume is limited.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. patent applicationSer. No. 13/367,911, entitled “Systems and Methods for Packaging andTransporting Bulk Materials,” filed Feb. 7, 2012, which claims priorityto U.K. Patent Application No. 1115601.5, entitled “Transport ofGranular Materials,” filed Sep. 9, 2011 and U.S. Provisional PatentApplication No. 61/440,202, entitled “Containerized Coal,” filed Feb. 7,2011, the disclosure of each of which is incorporated herein byreference in its entirety. This application also claims priority to U.S.Provisional Patent Application No. 61/644,166, entitled “Systems andMethods for Packaging and Transporting Bulk Materials,” filed May 8,2012, the disclosure of which is incorporated herein by reference in itsentirety.

BACKGROUND

The embodiments described herein relate to systems and methods forpackaging and transporting a bulk material. More particularly, theembodiments described herein relate to systems and methods for packagingand transporting coal within a flexible container.

Recent reports indicate that the United States has about 263,781 billiontons of recoverable coal. Yet, surprisingly, the U.S. exports onlyapproximately 90 million tons per year. In contrast, Russia exports 116million tons per year out of its estimated 173,074 billion tons ofrecoverable coal, and Australia exports 259 million tons per year eventhough it is estimated to have only one-third of the recoverable tons ofthe United States (84,437 billion tons).

One reason why the U.S. exports so little coal is because knowntransportation facilities and methods limit the ability to ship coal.According to known methods, coal is transported in its raw form via bulkcarrier vessels (for intercontinental transport), and via open railcars, barges, slurry pipelines and trucks (for intra-continentaltransport). Numerous factors limit the capacity of such transport means,including the lack of suitable deep draught ports and limitedavailability of coal handling facilities that can handle hazardousmaterials.

Known bulk transport processes utilized in the United States and othercoal producing countries are also inefficient and environmentallyunsound. In particular, after extraction, coal is typically loaded ontoopen trucks using construction equipment and conveyor systems, and thentransported to a railhead. At the railhead, the coal is unloaded andstored outdoors in large open piles until further transport is arrangedat a later point in time. When further transport is scheduled, the coalis reloaded onto available trains, typically in open, bulk rail cars.

When coal is destined for overseas locations, such as Asia, it isconveyed by rail car to ports that can handle bulk materials. Accordingto known methods, at these ports, coal is unloaded and stored outdoorsin large open piles until it is scheduled for loading on a vessel. Oncea vessel arrives for transporting the coal, the coal is loaded onto oneor more bulk holds of the vessel. Once the vessel arrives at itsdestination port, the coal is unloaded, stored and reloaded for furthertransport by land or rail to the generating plant or another end user.At the generating plant, the coal is again unloaded and stored outdoorsin a large open pile, where it remains until it is needed. Thus, atmultiple stages during known methods of transportation, coal is loaded,unloaded, stored, and reloaded. This repetitive loading, unloading,storage and re-loading of bulk material is highly inefficient.

Further, at each stage in the transportation process, coal is exposed toair and earth. Such practices are environmentally unsound, as coal dustis environmentally hazardous. Moreover, highly acidic materials canleach from storage piles into nearby aquifers. In addition, product islost to the effects of wind and rain, having a negative economic impact.

The lack of deep-water ports can also be a limiting factor in the exportof coal using known methods. For example, there are a limited number ofdeep-water ports throughout the U.S., particularly the west coast.Although most all U.S. ports can typically accommodate bulk vessels ofthe Handy class, which typically have a capacity in the range of35-40,000 tons, most U.S. ports cannot accommodate larger bulk transportships vessels. For example, most U.S. ports cannot accommodate largedraught vessels, such as Panamax vessels (with a capacity in the rangeof 60-80,000 tons) and Cape vessels (with a capacity of 100-150,000 ormore tons). While many west coast ports are seeking to expand theirability to accommodate larger bulk ships, these efforts have beendelayed or prevented by cost, environmental laws and regulations, andcommunity-based concerns. As a result, coal suppliers and exporters havehad no choice but to incur the high costs associated with transport viaHandy sized vessels through busy ports, shipping via Canadian ports ortopping off in Canadian and other country's ports.

Until recently, Asian countries have been supplied with the majority oftheir coal requirements from China, Australia, Indonesia, South Africaand Russia. Because China has now become a net importer of coal,however, there is increased demand for large bulk carrier capabilities,and several port initiatives have been undertaken to address thesedeficiencies. Unfortunately, these initiatives, which are often relatedto changes in the infrastructure related to shipping, are costly,long-term projects that are facing increasing local and nationalconcerns over the environmental impact of current handling and transportmethods for coal.

Known bulk transport methods are also limited in their ability todeliver different grades of material, including value-added forms ofcoal, such as processed coal. Specifically, when transported by bulkcarrier according to known methods, it is difficult to segregatematerials, and to maintain their quality. While bulk transport methodsmay be acceptable for transport of raw coal, they are often not adequatefor transport of a variety of forms of processed coal to multiple endusers, except by inclusion in fluidized beds or pipelines. However,fluidized beds and pipelines are expensive to construct, maintain and/orutilize.

Although intermodal containerization of goods has made transportation ofgoods significantly more efficient than other transportation methods,bulk commodities, such as coal, have not been able to benefit from theintermodal containerized transport systems for a variety of reasons. Forexample, one such reason is that coal is subject to spontaneouscombustion when exposed to air and pressure. Thus, shipping coal bycontainer according to known systems and methods can increase thelikelihood of spontaneous combustion.

Thus a need exists for improved systems and methods packaging andtransporting a bulk material.

SUMMARY

Apparatus, systems, and methods for housing a bulk material within aflexible container are described herein. In some embodiments, a methodincludes maintaining a flexible container in an expanded configurationto define an interior volume. A bulk material is conveyed into theinterior volume of the expanded flexible container. The flexiblecontainer is then moved from the expanded configuration to a collapsedconfiguration, such that movement of the bulk material within theinterior volume is limited.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a flexible container, according toan embodiment in an expanded configuration while being filled with abulk material.

FIG. 2 is a schematic illustration of the flexible container of FIG. 1,in the expanded configuration.

FIG. 3 is a schematic illustration of the flexible container of FIG. 1,in a collapsed configuration.

FIGS. 4 and 5 are schematic illustrations of a flexible containeraccording to an embodiment, in first configuration and a secondconfiguration, respectively.

FIGS. 6A-6C are perspective views of flexible containers, according tovarious embodiments.

FIG. 7 is a front view of a portion of the flexible container of FIG.6A.

FIG. 8 is a front view of a bulkhead included in the flexible containerof FIG. 6A.

FIG. 9 is an illustration of a label included in the bulkhead of FIG. 8.

FIG. 10 is a rear view of the flexible container of FIG. 6A.

FIG. 11 is a side view of the flexible container of FIG. 6A.

FIG. 12 is a front view of a portion of the flexible container of FIG.6A.

FIG. 13 is a bottom view of the flexible container of FIG. 6A.

FIG. 14 is a schematic illustration of a device for packaging and/orshaping a flexible container, according to an embodiment.

FIG. 15 is a perspective view of a container, according to anembodiment.

FIG. 16 is a top perspective view of a container, according to anembodiment.

FIG. 17 is a bottom perspective view of a container, according to anembodiment.

FIG. 18 is a bottom perspective view of a container, according to anembodiment.

FIG. 19 is a perspective view of a container, according to anembodiment.

FIG. 20 is a schematic illustration of a valve assembly included in aflexible container, according to an embodiment.

FIG. 21 is a perspective view of a sliding hatch and release mechanismincluded in a container, according to an embodiment.

FIG. 22 is a perspective view of a loading and unloading device includedin the container of FIG. 21.

FIGS. 23A-23C are flow charts illustrating methods for storing andtransporting a bulk material, according to various embodiments.

FIG. 24 is a flowchart illustrating a method for transporting a bulkmaterial, according to an embodiment.

FIG. 25 is a perspective view of a flexible container, according to anembodiment.

FIGS. 26-28 are schematic illustrations of flexible containers withbuffer ribs, according to various embodiments.

DETAILED DESCRIPTION

Apparatus, systems, and methods for housing a bulk material within aflexible container are described herein. In some embodiments, a flexiblecontainer includes a container body and a flexible cover. The containerbody defines an interior volume and includes a side wall that defines anopening. The opening is configured to receive a bulk materialtherethrough such that the bulk material can be disposed within aninterior volume of the container body. In some embodiments, for example,the opening can have a non-circular shape to accommodate a deliverymember, such as a coal conveyer. The flexible cover can be coupled tothe side wall about the opening. The cover is configured to fluidicallyisolate the interior volume from a volume substantially outside of theflexible container.

In some embodiments, a method includes maintaining a flexible containerin an expanded configuration to define an interior volume. A bulkmaterial is conveyed into the interior volume of the expanded flexiblecontainer. The flexible container is then moved from the expandedconfiguration to a collapsed configuration, such that movement of thebulk material within the interior volume is limited. For example, movingthe flexible container into the collapsed configuration can includereducing the head space of the container such that movement of a firstportion of the bulk material relative to a second portion of the bulkmaterial is impeded.

In some embodiments, a flexible container includes a first portion,constructed from a first material, and a second portion, constructedfrom a second material. The flexible container defines an interiorvolume and is placed in an expanded configuration when the interiorvolume receives a bulk material, such as, for example raw or processedcoal. The flexible container is configured to be moved from the expandedconfiguration to a collapsed configuration when the bulk material isdisposed within the interior volume via a reduction in pressure withinthe interior volume. The first portion is configured to deform a firstamount when the flexible container is moved from the expandedconfiguration to the collapsed configuration. The second portion isconfigured to deform a second amount, substantially different than thefirst amount.

In some embodiments, a system includes a rigid shipping container and aflexible container configured to be coupled within the rigid shippingcontainer. The flexible container defines an interior volume and can beplaced in an expanded configuration when the interior volume receives abulk material. The flexible container is configured to be moved from theexpanded configuration to a collapsed configuration when the bulkmaterial is disposed within the interior volume via a reduction inpressure within the interior volume. The system further includes atleast one flexible tether configured to anchor the flexible containerwithin the rigid shipping container to form the system. The system isdevoid of a dunnage bag and/or a bulwark. Similarly stated, the bulkmaterial can be coupled within the rigid shipping container solely viathe at least one flexible tether.

In some embodiments, a method includes disposing a flexible containerwithin a rigid container. The flexible container is magnetically coupledto the rigid container, such that an interior volume is defined withinthe flexible container. A bulk material is conveyed into the expandedinterior volume of the flexible container. The pressure within theinterior volume can be reduced, such that a pressure differentialbetween the interior volume and a volume outside the interior volumeovercomes the magnetic coupling. In some embodiments, when the flexiblecontainer is decoupled from the rigid container, the interior volume ofthe flexible container can define a collapsed interior volume. In someembodiments, the pressure within the interior volume can be reduced toeliminate substantially all head space between the bulk material and theflexible container, such that the volume of the flexible container isapproximately equal to the volume of the bulk material.

In some embodiments, a flexible container having a magnetic portion canbe magnetically coupled to a side wall of a rigid shipping container, todefine an interior volume within the flexible container. The interior ofthe flexible container can, for example, have a volume and/or shapeapproximately equal to the interior volume of the rigid shippingcontainer when the flexible container is magnetically coupled thereto. Abulk material can be conveyed into the interior volume of the flexiblecontainer. The flexible container can be moved from an expandedconfiguration to a collapsed configuration by decoupling the magneticportion of the flexible container from the rigid shipping container.When decoupled, the magnetic portion of the flexible container can bespaced apart from the side wall of the rigid shipping container.

In some embodiments, a system includes a rigid shipping container and aflexible container configured to be coupled within the rigid shippingcontainer. The flexible container defines an interior volume and can beplaced in an expanded configuration when the interior volume receives abulk material. The flexible container is configured to be moved from theexpanded configuration to a collapsed configuration when the bulkmaterial is disposed within the interior volume via a reduction inpressure within the interior volume. The system further includes atleast one tether including a first portion and a second portion. Thefirst portion is configured to be coupled to the flexible container. Thesecond portion is configured to be coupled to the rigid shippingcontainer. The tether defines a length configured to change when theflexible container is moved between the expanded configuration and thecollapsed configuration.

In some embodiments, a method includes conveying a bulk material into aninterior volume of a flexible container via an opening defined by theflexible container. The method further includes coupling a cover aboutthe opening to fluidically isolate the interior volume from a volumeoutside the flexible container. The method further includes reducing thepressure within the interior volume after the cover is coupled to theflexible material to move the flexible container into a collapsedconfiguration. In this manner, the bulk material and the flexiblecontainer can collectively form a substantially solid body that can behandled and/or shipped.

As used herein, the term “flexible” and/or “flexibility” relates to anobject's tendency towards deflection, deformation, and/or displacementunder an applied force. For example, a material with a greaterflexibility is more likely to deflect, deform and/or be displaced whenexposed to a force than a material having a lower flexibility. Similarlystated, a material having a higher degree of flexibility can becharacterized as being less rigid than a material having a lower degreeof flexibility. Flexibility can be characterized in terms of the amountof force applied to the object and the resulting distance through whicha first portion of the object deflects, deforms, and/or displaces withrespect to a second portion of the object. In certain situations, thiscan be depicted graphically as a stress-strain curve. Whencharacterizing the flexibility of an object, the deflected distance maybe measured as the deflection of a portion of the object different thanthe portion of the object to which the force is directly applied. Saidanother way, in some objects, the point of deflection is distinct fromthe point where force is applied.

Flexibility is an extensive property of the object being described, andthus is dependent upon the material from which the object is formed andcertain physical characteristics of the object (e.g., shape of theobject, number of plies of material used to construct the object, andboundary conditions). For example, the flexibility of an object can beincreased or decreased by selectively including in the object a materialhaving a desired modulus of elasticity, flexural modulus and/orhardness. The modulus of elasticity is an intensive property of (i.e.,is intrinsic to) the constituent material and describes an object'stendency to elastically (i.e., non-permanently) deform in response to anapplied force. A material having a high modulus of elasticity will notdeflect as much as a material having a low modulus of elasticity in thepresence of an equally applied force. Thus, the flexibility of theobject can be increased, for example, by introducing into the objectand/or constructing the object of a material having a relatively lowmodulus of elasticity.

Similarly, the flexural modulus is used to describe the ratio of anapplied stress on an object in flexure to the corresponding strain inthe outermost portions of the object. The flexural modulus, rather thanthe modulus of elasticity, is used to characterize certain materials,for example plastics, that do not have material properties that aresubstantially linear over a range of conditions. An object with a firstflexural modulus is more elastic and has a lower strain on the outermostportions of the object than an object with a second flexural modulusgreater than the first flexural modulus. Thus, the flexibility of anobject can be increased by including in the object a material having arelatively low flexural modulus.

The flexibility of an object constructed from a polymer can beinfluenced, for example, by the chemical constituents and/or arrangementof the monomers within the polymer. For example, the flexibility of anobject can be increased by decreasing a chain length and/or the numberof branches within the polymer. The flexibility of an object can also beincreased by including plasticizers within the polymer, which producesgaps between the polymer chains.

As used herein, the terms “expandable,” “expanded configuration,”“collapsible” and/or “collapsed configuration” relate to a flexiblecontainer defining a first cross-sectional area (or volume) and a secondcross-sectional area (or volume). For example, a flexible container ofthe types described herein, can define a larger cross-sectional area (orvolume) when in an expanded configuration than the cross-sectional area(or volume) of the flexible container in the collapsed configuration.Expandable components described herein can be constructed from anymaterial having any suitable properties. Such material properties caninclude, for example, a flexible material having a high tensilestrength, high tear resistance, high puncture resistance, a suitablelevel of compliance (e.g., the expandable components ability to expandappreciably beyond its nominal size) and/or a suitable modulus ofelasticity (e.g., as described above).

In some embodiments, for example, an expandable component (e.g., aflexible container) can include at least a portion constructed from ahigh-compliant material configured to significantly elastically deformwhen expanded. In other embodiments, an expandable component (e.g., theflexible container) can include at least a portion constructed from alow-compliant material (e.g., a material configured to expand withoutsignificant elastic deformation). The compliance of an expandablecomponent defining, for example, an interior volume, is the degree towhich a size of the expandable component (in an expanded state) changesas a function of the pressure within the interior volume. For example,in some embodiments, the compliance of a flexible container can be usedto characterize the change in the diameter or perimeter length of theexpanded flexible container as a function of the pressure within theinterior volume defined by the flexible component. In some embodiments,the diameter or perimeter length of an expanded component characterizedas a low-compliant component can change by zero to ten percent over therange of pressure applied to the interior volume thereof (e.g., either apositive pressure or a vacuum). In other embodiments, the diameter orperimeter length of an expanded component characterized as ahigh-compliant component can change as much as 30 percent, 50 percent,100 percent or greater.

Because the overall characteristics of a flexible container, includingthe compliance, can be a function of both the material from which theflexible container is constructed and the structural characteristics ofthe flexible container, the material from which the flexible containeris constructed can be selected in conjunction with the desiredstructural characteristics of the flexible container. For example, insome embodiments, a flexible container can include a first portiondefining a first compliance and/or flexibility and a second portiondefining a second compliance and/or flexibility. In such embodiments, itcan be desirable that the first portion (e.g., a bottom portion) includea lower compliance and/or greater stiffness than the second portion(e.g., a top portion). Thus, the first portion of the flexible containercan be configured to deform less under increased or decreased pressurewithin an interior volume than the second portion. For example, in someembodiments, a force exerted by a bulk material (e.g., the weight of thebulk material) may be such that substantial deformation of the firstportion could result in tearing of the material.

As used herein, the term “bulk material” relates to a cargo that istransported in large quantities in the absence of individual packaging.Bulk material and/or bulk cargo can be very dense, corrosive, orabrasive. For example, a bulk material can be bauxite, sand, gravel,copper, limestone, salt, cement, fertilizers, plastic granular, resinpowders, coal (e.g., lignite, bituminous and/or anthracite, etc.),grains, iron (e.g., iron ore, direct reduced iron, pig iron, etc.),gasoline, liquefied natural gas, petroleum, and/or the like. Some bulkmaterials, for example, coal, can define a low flowability, can beabrasive, can define an uneven weight distribution, and canspontaneously combust. Direct reduced iron can be extremely reactive,corrosive, flammable, susceptible to re-oxidation, overheating, and thegeneration of highly combustible hydrogen if left unprotected. Exposureof direct reduced iron to seawater can be particularly dangerous. Incontrast, a slurry or flowable material can be less abrasive and can beeasily distributed. Therefore, handling, packaging and/or shipping of abulk material can pose different challenges than the handling, packagingand/or shipping of a slurry or flowable material.

Some embodiments described herein include flexible containers operableto substantially hermetically seal the bulk material from the outsideatmosphere. The atmosphere of the interior volume of the flexiblecontainer can be evacuated and/or replaced with an inert substance, suchas, for example, nitrogen, carbon dioxide, argon, etc.

FIG. 1 is a schematic illustration of a flexible container 100,according to an embodiment. The flexible container 100 includes acontainer body 110 and a cover 160 and is configured to move between anexpanded configuration (e.g., FIGS. 1 and 2) and a collapsedconfiguration (e.g., FIG. 3). The flexible container 100 includes a sidewall 112 and defines an interior volume 111 within the container body110. The flexible container 100 can be any suitable shape, size, orconfiguration. For example, in some embodiments, the flexible container100 can define an irregular shape as shown in FIG. 1. In otherembodiments, a flexible container 100 can have a rectangular prismshape, a cylindrical shape or the like.

The flexible container 100 can be formed from any suitable material ormaterial combination. For example, in some embodiments, the flexiblecontainer 100 can be formed from polyethylene, ethylene vinyl acetate(EVOH), amorphous polyethylene terephthalate (APET), polypropylene (PP),high-density polyethylene (HDPE), polyvinylchloride (PVC), polystyrene(PS), polyethylmethacrylate (EMA), metallocene polyethylene (plastomermetallocene), low-density polyethylene (LDPE), high-melt strength(LDPE), ultra-low-density linear polyethylene (ULLDPE), linearlow-density polyethylene (LLDPE), K-resin, polybutadiene, and/ormixtures, copolymers, and/or any combination thereof. As used herein theterm “copolymer” includes not only those polymers having two differentmonomers reacted to form the polymer, but two or more monomers reactedto form the polymer.

In some embodiments, the container body 110 can be constructed frommultiple layers of material. For example, in some embodiments, theflexible container 100 can include an inner layer and an outer layer. Insuch embodiments, the inner and/or outer layer can be formed from anysuitable material or material combination such as, for example, thosedescribed above. In other embodiments, the flexible container 100 caninclude three or more layers. Furthermore, the layers from which thecontainer body 110 is constructed can be formed from a similar ordissimilar material. For example, in some embodiments, a first layer canbe formed from a first material, a second layer can be formed from asecond material, and a third layer can be formed from a third material.In other embodiments, one or more layers can be constructed from similarmaterials.

As shown, the side wall 112 defines an opening 113 having asubstantially non-circular shape. The opening 113 is configured toreceive a portion of a delivery member C, such as, for example, aconveyer, a chute, a pipe, or the like. In this manner, the deliverymember can convey a bulk material (not shown) into the interior volume111 defined by the container body 110 according to the methods describedherein. In some embodiments, the delivery mechanism is a conveyer Cconfigured to transfer coal to the interior volume 111 via the opening113. In other embodiments, the bulk material can be any suitablematerial of the types described herein. For example, the bulk materialcan be phosphate, coal, iron ore, direct reduced iron, mined ore, grain,and/or the like. In some embodiments, when the bulk material is beingconveyed into the interior volume 111, the container body 110 can bemaintained in an expanded (or partially expanded) configuration byconveying an inflation fluid (e.g., air, nitrogen or any other suitablegas) into the interior volume. The inflation fluid can be conveyed intothe interior volume 111 via the opening 113. Similarly stated theinflation fluid can be conveyed into the interior volume 111 via thesame opening through which the bulk material is conveyed. In otherembodiments, the container body 110 can be maintained in the expanded(or partially expanded) configuration by any suitable mechanism, such asby attaching the corners of the container body 110 to a rigid structurevia tethers and/or cords.

In some embodiments, the conveyer C can be configured to telescope(i.e., change lengths) within the container body 110. For example, insome embodiments, the conveyer C can be disposed through the opening 113and within the interior volume 111 of the container body 110 such thatthe conveyer C can transfer the bulk material to a particular locationthe interior volume 111. In this manner, the container body 110 can beloaded from back to front. Similarly stated, according to this method,when the conveyer C transfers the bulk material to the interior volume111, the conveyer C can be configured to retract (move from the backportion towards the front portion) with respect to the side wall 112. Inthis manner, the bulk material can be loaded into the container body 110evenly (i.e., with a suitable weight distribution) thus reducing loadshifting during transport.

As shown in FIG. 2, after the desired quantity of the bulk materialdisposed within the interior volume 111 of the container body 110, theconveyer C can be removed from the interior volume 111 via the opening113. The cover 160 can then be disposed about the opening 113 tofluidically isolate the interior volume 111 from a volume substantiallyoutside the container body 110. Similarly stated, the cover 160 isconfigured to fluidically and/or hermetically seal the container body110.

The cover 160 can be constructed from any suitable material and can becoupled to the container body 110 by any suitable means. For example, insome embodiments, the cover 160 can be formed from a similar material asat least a portion of the container body 110 (e.g., the cover 160 can beformed from a flexible material). The cover 160 can be coupled to theside wall 112, for example, via an adhesive, adhesive strip, a chemicalweld or the like. In other embodiments, the cover 160 can be coupled tothe side wall 112 via a zipper style fit. In some embodiments, the cover160 and the side wall 112 can define a substantially planar surface whenthe flexible container 100 is in the expanded configuration. In thismanner, the container body 110 and the cover 160 can form asubstantially continuous surface after the cover 160 is coupled to thecontainer body 110. By avoiding a protruding cover, this arrangement canresult in ease of packaging, handling and/or shipping of the flexiblecontainer 100.

As shown in FIG. 3, the flexible container 100 can be placed in thecollapsed configuration. More specifically, container body 110 and thecover 160 can be placed in the collapsed configuration by evacuating atleast a portion of a gas within the interior volume 111 via a port (notshown). In some embodiments, the cover 160 defines the port. In otherembodiments, the container body 110 (e.g., the side wall 112) can definethe port. In this manner, the port can be engaged by, for example, avacuum source such that the pressure within the interior volume 111 ofthe container body 110 is reduced. The reduction of the pressure withinthe interior volume 111 can be such that container body 110 deforms.Similarly stated, the vacuum source can exert a suction force on theinterior volume 111 thereby urging at least a portion of the containerbody 110 to deform under the vacuum force. Furthermore, the vacuumsource can be configured to expose interior volume 111 to the suctionforce such that the interior volume 111 is substantially devoid of a gas(e.g., air). Said another way, the interior volume 111 is exposed to anegative pressure and thereby urges the container body 110 tosubstantially conform to a contour of the bulk material disposedtherein.

In some embodiments, the flexible container 100 can collapse (e.g.,conform to the bulk material) such that the bulk material disposedwithin the container body 110 can act as a substantially solid mass. Forexample, in some embodiments, the flexible container 100 can collapsesuch that a distance between adjacent parts of a bulk material isreduced. In this manner, the movement of specific parts (e.g.,particles, pellets, grains, chunks, portions, and/or the like) of thebulk material is reduced relative to adjacent parts of the bulkmaterial. Thus, the potential of load shifting within the flexiblecontainer 100 is reduced. In some embodiments, the substantialevacuation of the gas (e.g., air) within the flexible container 100 canreduce the risk of spontaneous combustion of the bulk material (e.g.,coal).

In some embodiments, the flexible container 100 can be placed intoand/or secured within a rigid shipping container. In such embodiments,the flexible container 100 can include a set of tethers (not shown inFIGS. 1-3) configured to couple the flexible container 100 to an innersurface of the rigid container. For example, in some embodiments, thetethers can include a first portion that can be coupled to the flexiblecontainer 100 and a second portion that can be coupled to the rigidcontainer. In some embodiments, the tethers can be formed of a flexiblematerial such that with the tether coupled to the flexible container 100and the rigid container, a length of the tether can extend when theflexible container 100 is moved from the expanded configuration to thecollapsed configuration. Similarly stated, the flexible container 100can be disposed within the rigid container such that the flexiblecontainer 100 moves relative to the rigid container (e.g., away from aset of walls of the rigid container) thereby urging the length of thetethers to extend. In some embodiments, the flexible container 100 canfurther include a bumper portion configured to engage a surface of therigid container and absorb a portion of a force from any load shiftingwithin the rigid container. The bumper portions can be any suitableportion. For example, in some embodiments, the bumper portions includeone or more sleeves configured to receive a shock absorbing member. Inother embodiments, the bumper portions can be inflated with a gas (e.g.,air). Similarly stated, in some embodiments, the flexible container 100can include an integrated dunnage system to minimize the transfer ofload to (or deformation of) the rigid container within which theflexible container 100 is disposed.

In some embodiments, a flexible container can include portions formedfrom different materials. In this manner, the rate of deformation of theflexible container when moved to the collapsed configuration can varyspatially. For example, FIGS. 4 and 5 show a flexible container 200 thatincludes a container body 210 and defines an interior volume 211therein. The flexible container 200 is configured to move between anexpanded configuration (e.g., FIG. 4) and a collapsed configuration(e.g., FIG. 5). Although the flexible container 200 is shown as defininga volume when in the collapsed configuration, in other embodiments, theflexible container 200 can be configured to be moved to a collapsedconfiguration in which the container defines substantially no volumetherein (e.g., a container storage configuration). The flexiblecontainer 200 can be any suitable shape or size. For example, in someembodiments, the flexible container 200 can define a cylindrical shape.The flexible container 200 can be formed from any suitable material,such as any suitable materials of the type described herein or anycombination thereof.

As shown in FIG. 4, the container body 210 includes a first portion 220and a second portion 240. The first portion 220 and the second portion240 can be formed from a similar or dissimilar material, and can becharacterized by a similar or dissimilar stiffness and/or flexibility.The first portion 220 is formed from a first material that has a firststiffness and the second portion 240 is formed from a second material,different than the first material, and which has a second stiffness,different from the first stiffness. In some embodiments, the firstmaterial of the first portion 220 is substantially stiffer than thesecond material of the second portion 240.

In some embodiments, the first portion 220 and the second portion 240can be coupled together to form the container body 210. In suchembodiments, the first portion 220 and the second portion 240 can becoupled in any suitable manner. For example, in some embodiments, thefirst portion 220 and the second portion 240 can be coupled viaadhesive, chemical weld or bond, sewn, insertion into a flange orcoupling device, and/or the like. In this manner, the first portion 220and the second portion 240 define a substantially fluidic and/orhermetic seal. Similarly stated, the first portion 220 is coupled to thesecond portion 240 to define a non-permeable coupling (e.g., air tight).

In some embodiments, the flexible container 200 includes multiple layers(not shown). For example, in some embodiments, the first portion 220 andthe second portion 240 can each be constructed from multiple layers. Insuch embodiments, the multiple layers of the first portion 220 and/orthe second portion 240 can be formed from any suitable material such asthose described herein. Furthermore, the multiple layers of the firstportion 220 and/or the second portion 240 can be formed from similar ordissimilar materials. For example, a first layer can be formed from afirst material and a second layer can be formed from a second material.In some embodiments, one or more of the multiple layers included in thesecond portion 240 can be similar to one or more of the multiple layersof the first portion 220. The multiple layers of the first portion 220and the multiple layers of the second portion 240 can be coupledtogether to define the fluidic and/or hermetic seal (e.g., as describedabove).

When in the expanded configuration (e.g., FIG. 4), the flexiblecontainer 200 can receive a bulk material (not shown) such that the bulkmaterial is disposed within the interior volume 211. With the desiredamount of bulk material disposed within the interior volume 211, theflexible container 200 can be moved from the expanded configuration tothe collapsed configuration, as shown in FIG. 5. More specifically, apressure within the interior volume 211 can be reduced such that theflexible container 200 collapses in response to the reduced pressure. Insome embodiments, the flexible container 200 can include a port (notshown in FIGS. 4 and 5) that can be engaged by, for example, a vacuumsource configured to reduce the pressure within the interior volume 211of the container body 210. Similarly stated, the vacuum source can exerta suction force on the interior volume 211 thereby urging at least aportion of the container body 210 to deform under the force.Furthermore, the vacuum source can be configured to expose the interiorvolume 211 to the suction force such that the interior volume 211 can besubstantially evacuated (i.e., substantially devoid of a gas). Saidanother way, the interior volume 211 is exposed to a negative pressureand thereby urges the container body 210 to substantially conform to acontour of the bulk material disposed therein.

As described above, the first portion 220 can be formed from the firstmaterial and define the first stiffness and the second portion 240 canbe formed from the second material and define the second stiffness. Inthis manner, with the suction force applied to the interior volume 211of the container body 210, the first stiffness of the first portion 220is such that the first portion 220 deforms a first amount, as shown bythe arrows A₁ in FIG. 5. Similarly, the second stiffness of the secondportion 240 is such that the second portion 240 deforms a second(different) amount, as shown by the arrows A₂ in FIG. 5. Furthermore,with the stiffness of the second portion 240 being substantially lessthan the first portion 220, the second portion 240 deflects (e.g.,deform) substantially more than the first portion 220.

In some embodiments, the flexible container 200 can collapse (e.g.,conform to the bulk material) such that the bulk material disposedwithin the container body 210 can act as a substantially solid mass. Forexample, in some embodiments, the flexible container 200 can collapsesuch that a distance between adjacent portions and/or components of thebulk material is reduced. In this manner, the movement of specific parts(e.g., particles, pellets, grains, chunks, portions, and/or the like) ofthe bulk material is reduced relative to adjacent parts of the bulkmaterial. Similarly stated, when the flexible container 200 is movedfrom the expanded configuration to the collapsed configuration, the bulkmaterial therein can be moved from a flowable (or partially flowable)state to a substantially non-flowable state. Thus, the potential of loadshifting of the bulk material within the flexible container 200 isreduced. Accordingly, the flexible container 200 can be strapped and/oranchored to and/or within a shipping platform or container using tethersand/or straps. In some embodiments, for example, the flexible container200 can be coupled within any of the rigid shipping containers describedherein (e.g. the rigid shipping container 465) without the need fordunnage bags, bulkheads and/or bulwarks to absorb load from the shiftingof the bulk material therein.

In some embodiments, the substantial evacuation of the gas (e.g., air)within the flexible container 200 can reduce the risk of spontaneouscombustion of the bulk material (e.g., coal, direct reduced iron, etc.).In some embodiments (e.g., when the bulk material is a food product),the substantial evacuation of the gas (e.g., air) within the flexiblecontainer 200 can reduce the risk contamination, reaction and/or thelike.

In some embodiments, the flexible container 200 can include one or morelayers that are monolithically formed and are disposed within the firstportion 220 and the second portion 240 to act as a liner (not shown inFIGS. 4 and 5). The inner layer (or liner) can be formed from anysuitable material and can include any suitable material characteristicsuch as, for example, flexibility, durometer, compliance, abrasionresistance, and/or the like. For example, in some embodiments, theflexible container 200 can include the inner layer and the first portion220 and the second portion 240. The first portion 220 and the secondportion 240 can be coupled together such that the inner layer isdisposed within the interior volume 211 defined by the first portion 220and the second portion 240 of the container body 210. In someembodiments, the inner layer abrasion resistant and fluidicallypermeable. In this manner, the inner layer can protect the first portion220 and the second portion 240 from sharp portions and/or pointsincluded in the bulk material. Moreover, when the flexible container 200is moved to the collapsed configuration, the suction force (e.g., thevacuum) can pass through the inner layer and exert at least a portion ofthe suction force of the first portion 220 and the second portion 240.Therefore, the first portion 220 and the second portion 240 can collapseto place the flexible container 200 in the collapsed configuration.

While shown in FIGS. 1-3 as defining an irregular shape, in someembodiments a flexible container can define a substantially rectangularshape. For example, as shown in FIGS. 6A and 7-13, a flexible container300 includes a container body 310, a side wall 312, a bulkhead 325, anda cover 360. FIGS. 6B and 6C show a flexible container 364 that differsfrom the flexible container 300 in that, among other things, theflexible container 364 includes a series of magnets 365. Many aspects ofthe flexible container 364 are similar to those of the flexiblecontainer 300, and thus the details of the flexible container 364 arenote discussed in detail below. The flexible container 300 and theflexible container 364 can be any suitable size, for example, a sizeconfigured to fit within a commercially-available shipping container, orany of the rigid containers shown and described herein. For example, theflexible container 300 defines a length L, a height H, and a width W. Insome embodiments, the length L can be approximately 20 feet, the heightH can be approximately 8 feet, and the width can be approximately 7.5feet. In other embodiments, the length L can be approximately 40 feet,the height can be approximately 8 feet, and the width can beapproximately 7.5 feet.

The container body 310 includes a first portion 320 and a second portion340 and defines an interior volume 311. The first portion 320 and thesecond portion 340 can be formed from any suitable material. In someembodiments, the first portion 320 and/or the second portion 340 can beformed from a similar or dissimilar material and can define a similar ordissimilar stiffness (e.g., flexibility). For example, the first portion320 is formed from a first material that has a first stiffness, and thesecond portion 340 is formed from a second material, different than thefirst material, that has a second stiffness, different from the firststiffness. In some embodiments, at least a portion of the first portion320 is formed from polyethylene woven fabric (e.g., 120 g/sqm) and atleast a portion of the second portion 340 is formed from polyethylenefilm (e.g., 140 microns thick). Polyethylene is flexible, inert, andcreates a lower static charge than, for example, polypropylene. Thus,polyethylene is a suitable material for the transportation of certainbulk materials such as, for example, coal. Furthermore, with the firstportion 320 formed from polyethylene woven fabric, the first portion 320is substantially stiffer than the second portion 340 formed frompolyethylene film. As described herein, this arrangement can result indifferent rates of deformation when the container 300 is moved from anexpanded configuration to a collapsed configuration.

As shown in FIGS. 6A-C, the first portion 320 and the second portion 340are coupled together to form the container body 310. The first portion320 and the second portion 340 can be coupled in any suitable manner.For example, in some embodiments, the first portion 320 and the secondportion 340 can be coupled via adhesive, chemical weld or bond, sewn,insertion into a flange or coupling device, and/or the like. In thismanner, the first portion 320 and the second portion 340 define asubstantially fluidic and/or hermetic seal. Similarly stated, the firstportion 320 is coupled to the second portion 340 such as to define anon-permeable coupling (e.g., air tight). In other embodiments, thefirst portion 320 and the second portion 340 form a monolithicallyconstructed container body 310.

The flexible container 300 includes multiple layers (not shown). In someembodiments, the first portion 320 and/or the second portion 340 includemultiple layers. In some embodiments, the flexible container 300 caninclude one or more layers substantially independent of the firstportion 320 and/or the second portion 340 (e.g., a liner). In suchembodiments, the multiple layers of the first portion 320 can be formedfrom any suitable material such as those described above. Furthermore,the multiple layers of the first portion 320 can be formed from similaror dissimilar materials. For example, an inner layer can be formed frompolyethylene woven fabric a first material and a second layer can beformed from a second material. Similarly, the multiple layers of thesecond portion 340 can be formed from any suitable material. In someembodiments, the multiple layers of the second portion 340 are formedfrom a similar or dissimilar material. In some embodiments, one or moreof the multiple layers included in the second portion 340 can be similarto one or more of the multiple layers of the first portion 320. Themultiple layers of the first portion 320 and the multiple layers of thesecond portion 340 can be coupled together to define the fluidic and/orhermetic seal (e.g., as described above).

As shown in FIG. 7, the side wall 312 defines a substantiallyrectangular-shaped opening 313. The opening 313 can receive a portion ofa delivery member (not shown) configured to convey a bulk material (notshown) to be disposed within the interior volume 311 defined by thecontainer body 310. For example, in some embodiments, the deliverymember can be a conveyer configured to transfer raw coal to the interiorvolume 311 via the opening 313. In other embodiments, the deliverymechanism can be a hose configured to be coupled to the side wall 312such that the hose delivers processed coal to the interior volume 311via the opening 313.

In some embodiments, the delivery mechanism is configured to telescope(i.e., change lengths) within the container body 311, as describedabove. For example, in some embodiments, a conveyer can be disposedthrough the opening 313 and within the interior volume 311 of thecontainer body 313 such that the conveyer can transfer the bulk materialto the interior volume 311 such that the container body 310 is loadedfrom back to front. Similarly stated, as the conveyer transfers the bulkmaterial to the interior volume 311, the conveyer can be configured toretract with respect to the side wall 312. In this manner, the bulkmaterial can be loaded with a suitable weight distribution thus reducingload shifting during transport. In some embodiments, the flexiblecontainer 300 can include an internal telescoping member (not shown)configured to selectively convey a bulk material from a delivery member(e.g., distribute the bulk material within the interior volume).

The cover 360 includes a port 361 and is configured to be coupled to theside wall 312 about the opening 313. More particularly, the cover 360 iscoupled to the side wall 312 and about the opening 313 such that thecover 360 fluidically isolated the interior volume 311 from a volumesubstantially outside the container body 310. Similarly stated, thecover 360 is configured to fluidically and/or hermetically seal thecontainer body 310. The cover 360 can be formed from any suitablematerial, such as a similar material as at least a portion of thecontainer body 310. For example, in some embodiments, the cover 360 isformed from polyethylene film with a 140 micron thickness. In otherembodiments, the cover 360 can be any suitable thickness.

The cover 360 can be coupled to the side wall 312 in any suitablemanner. For example, as shown in FIG. 7, cover 360 is coupled to theside wall 312 via an adhesive strip 342. The adhesive strip 342 can beany suitable adhesive such as, for example, a glass fiber glue tape. Inthis manner, the cover 360 and the side wall 312 can define asubstantially planar surface when the flexible container 300 is in theexpanded configuration. As another example, as shown in FIGS. 6B and 6C,cover 360 is operable to be coupled to the side wall 312 via a magnetportion 366. Similarly stated, the cover 360 is configured to engage asubstantially flat surface of the side wall 312 such that the cover 360and the side wall 312 are substantially co-planar. Said another way, thecover 360 couples to a portion of the side wall 312 defining the opening313 that is substantially flat (e.g., does not include a mountingflange, ring, protrusion, and/or the like). The use of the adhesivestrip 342 and/or the magnetic portion 366 is such that when the cover360 is coupled to the side wall 312 the cover 360 fluidic and/orhermetic seal isolates the interior volume 311 defined by the containerbody 310. In other embodiments, the cover 360 can be coupled to the sidewall 312 using any suitable method, such as, for example, a chemicalweld.

The side wall 312 further includes a portion configured to which thebulkhead 325 is coupled (see e.g., FIG. 8). The bulkhead 325 isconfigured to provide mechanisms for absorbing load, handling and/ormanipulating the container 300. The bulkhead 325 can be any suitableshape, size, or configuration. For example, the bulkhead 325 issubstantially similar in height and width as the first portion 320 ofthe container body 310. In this manner, when coupled to the side wall312 the bulkhead 325 transfers a portion of a force (e.g., a load shiftduring transport) to the relatively stiff first portion 320 and not therelatively flexible second portion 340. The bulkhead 325 can be formedfrom any suitable material that includes any suitable weight. Forexample, in some embodiments, the bulkhead 325 is formed frompolypropylene woven fabric with a weight of 210 g/sqm. In this manner,the use of polypropylene woven fabric is such that the bulkhead issubstantially stiffer than the first portion 320 and/or the secondportion 340. Thus, in use the bulkhead 325 is less likely to deform whenthe flexible container 300 is placed in the collapsed configuration.

The bulkhead 325 includes a sleeve 321, a set of webbing strips 326, anda material label 335. As shown in FIG. 9, the material label 335 caninclude information associated with the flexible container 300. Thesleeve 321 is configured to extend from a surface of the bulkhead 325 todefine a void. In some embodiments, the sleeve 321 can be coupled to thebulkhead 325 in any suitable manner such as, for example, thosedescribed above. In other embodiments, the sleeve 321 can bemonolithically formed with the bulkhead 325. The sleeve 321 isconfigured to receive a shock absorbing member (not shown) within thevoid defined between the sleeve 321 and the bulkhead 325, as describedin further detail herein. The webbing strips 326 can be coupled to thebulkhead 325 in any suitable manner. For example, in some embodiments,the webbing strips 326 can be sewn to the bulkhead 325. In otherembodiments, the webbing strips 326 can be chemically welded and/orcoupled via adhesives. The webbing strips 326 include a set of loops327, a set of ratchet straps 328, and a set of tethers 355. In use, theflexible container 300 is configured to be disposed within a rigidcontainer (not shown) and the loops 327, the ratchet straps 328, and/orthe tethers 355 can engage an interior portion of the rigid container tocouple the flexible container 300 to the interior portion of the rigidcontainer.

Similarly, the second portion 320 and a rear portion of the flexiblecontainer 300 can include members configured to engage the interiorportion of the rigid container. For example, as shown in FIG. 10, therear portion can include an elastic band 314 configured to engage theinterior portion of the rigid container. The rear portion can furtherinclude corner caps 315 configured to protect the corners of theflexible container 300. In some embodiments, the corner caps 315 caninclude tethers and/or straps configured to engage the rigid container.

As shown in FIGS. 11 and 12, the second portion 340 includes a set ofattachment members 345 configured to receive a portion of the tethers355. The attachment members can be disposed on or within the secondportion 340 at any suitable position. For example, in some embodiments,the attachment members 345 can be disposed along a top surface of thesecond portion 340 at a distance D₁ from adjacent attachment members345. While shown in FIG. 11 as being substantially uniformly spaced, insome embodiments, the attachment members 345 can be spaced at any givendistance from adjacent attachment members 345.

As shown in FIG. 12, the attachment members 345 include a loop portion346 and a base 347. The base 347 is coupled to the second portion 340 ofthe container body 310. For example, in some embodiments, the base 347is coupled to the second portion 340 via adhesive strips. In someembodiments, the second portion 340 defines a channel configured toreceive the base 347 of the attachment member 345. The loop portion 346is configured to receive a portion of the tether 355. More specifically,the tether 355 includes a first portion 356 configured to couple to theloop portion 346 and a second portion 357 configured to couple to therigid container.

Although the flexible container 300 is described as being coupleable toa rigid container via the tethers 355, in other embodiments, theflexible container 300 or any of the flexible containers shown anddescribed herein can be coupled to and/or within a rigid container viaany suitable mechanism. Moreover, in some embodiments, the flexiblecontainer 300 or any of the flexible containers shown and describedherein can be removably coupled to and/or within a rigid container. Forexample, in some embodiments, magnets 365 can be attached to a flexiblecontainer 364 (which can be similar to the flexible container 300, asdiscussed above; see FIGS. 6B and 6C) to keep the bag in its inflated orexpanded configuration during loading. The magnets 365 can be coupled tothe side and/or top of the container body 310. The coupling of themagnets 365 to the container body 310 may be in the form of pockets orbattens, in which magnets 365 can be removably coupled to the containerbody. In other embodiments, the magnets 365 can be permanently attachedto the flexible container 364 during the manufacturing process such thatthe magnets 365 become an integral part of the flexible container 364.In some embodiments, multiple pockets can be provided on the flexiblecontainer 364 and the magnets 365 can be reconfigured depending on theconfiguration of the rigid structure into which the container body isplaced. In some embodiments, the container body 310 or a portion thereofis formed from a magnetic material.

As described below, in use, when the air is withdrawn from the flexiblecontainer 364 when a vacuum is applied (e.g., to move the flexiblecontainer 364 to a collapsed configuration), the magnets 365 detach fromthe rigid structure and the flexible container 364, and the contentstherein achieve a solid or semi-solid form as described herein. Themagnets 365 can be designed to have a magnetic field of sufficient forcesuch that the container body 310 is coupled to the rigid structure untilthe flexible container 364 is sufficiently filled, at which time, theforce of the magnets 365 is overcome by the weight of the fillermaterial and/or the applied vacuum, allowing the flexible container 364to pull away from the rigid structure.

In some embodiments, the magnets 365 can detach simultaneously. In otherembodiments, the magnets 365 are configured to detach in a definedmanner (i.e., the magnets 365 furthest from the opening of the containerdetaching first, and the magnets 365 closest to the opening of theflexible container 364 detaching last.

In use, the flexible container 300 (and/or the flexible container 364)is coupled to the rigid container (e.g., any of the rigid containersshown herein) and receives the bulk material via the opening 313. Insome embodiments, when the bulk material is being conveyed into theinterior volume 311, the container body 310 can be maintained in anexpanded (or partially expanded) configuration by conveying an inflationfluid (e.g., air, nitrogen or any other suitable gas) into the interiorvolume 311. The inflation fluid can be conveyed into the interior volume311 via the opening 313. Similarly stated the inflation fluid can beconveyed into the interior volume 311 via the same opening through whichthe bulk material is conveyed. This arrangement eliminates the need formultiple openings within the container body 310. Additionally, thismechanism for loading the container body 310 does not require afluid-tight coupling between the delivery member and the container body310. In other embodiments, the container body 310 can be maintained inthe expanded (or partially expanded) configuration by any suitablemechanism, such as by attaching the corners of the container body 310 toa rigid structure via the tethers 355.

With the desired amount received within the internal volume, the cover360 is coupled to the side wall 312 and the flexible container 300 isthen moved to the collapsed configuration. Expanding further, the port361 included in the cover 360 can be configured to act as an ingress oregress for a gas to be disposed within or expelled from the interiorvolume 311. For example, the port 361 can be engaged by a vacuum sourcesuch that the pressure within the interior volume 311 of the containerbody 310 is reduced. The reduction of the pressure within the interiorvolume 311 can be such that all or portions of the container body 310deform. Similarly stated, the vacuum source can exert a suction force onthe interior volume 311 thereby urging at least a portion of thecontainer body 310 to deform under the force. Furthermore, the vacuumsource can be configured to expose interior volume 311 to the suctionforce such that the interior volume 311 is substantially devoid of a gas(e.g., air). Said another way, the interior volume 311 is exposed to anegative pressure and thereby urges the container body 310 tosubstantially conform to a contour of the bulk material disposedtherein. In some embodiments (e.g., embodiments that include a magneticcoupling, as described above with the flexible container 364), thenegative pressure can be sufficient to overcome the magnetic couplingbetween the flexible container and the rigid container. Similarlystated, a pressure differential between the interior volume of theflexible container (e.g., container 364) and a volume outside of theinterior volume is sufficient to overcome the magnetic coupling. In someembodiments, the cover 360 is hingedly coupled to the container 300.

As described above, the first portion 320 can be formed from the firstmaterial (e.g., polyethylene woven fabric) and define the firststiffness and the second portion 340 can be formed from the secondmaterial (e.g., polyethylene film) and define the second stiffness. Inthis manner, with the suction force applied to the interior volume 311of the container body 310, the first stiffness of the first portion 320is such that the first portion 320 deforms a first amount. Similarly,the second stiffness of the second portion 340 is such that the secondportion 340 deforms a second amount. Furthermore, with the stiffness ofthe second portion 340 being substantially less than the first portion320, the second portion 340 deflects (e.g., deform) substantially morethan the first portion 320.

In some embodiments, the tethers 355 (FIGS. 11 and 12) are formed froman elastomeric material such that with the tethers coupled 355 to theflexible container 300 and a rigid container, a length of the tether 355extends when the flexible container 300 is moved from the expandedconfiguration to the collapsed configuration. This arrangement allowsthe flexible container 300 to be disposed and/or coupled within a rigidcontainer such that the flexible container 300 moves relative to therigid container (e.g., away from a set of walls of the rigid container)thereby urging the length of the tethers 355 to extend when the flexiblecontainer 300 is moved from the expanded configuration to the collapsedconfiguration.

In some embodiments, the flexible container 364 (FIGS. 6B, 6C) can becoupled to the rigid container via magnets 365 such that when theflexible container is moved from the expanded configuration to thecollapsed configuration, the magnets 365 decouple from the rigidcontainer. The magnets 365 can be decoupled by a force resulting fromdecreasing the pressure within the flexible container. Alternatively,the magnets 365 can be manually decoupled from the rigid container. Insome embodiments, the magnets 365 can be electromagnets which can bedecoupled from the rigid container via de-energization.

In some embodiments, the flexible container 300 (or the flexiblecontainer 364) can be moved to a collapsed configuration (e.g., canconform to the bulk material) such that the bulk material disposedwithin the container body 310 can act as a substantially solid mass. Forexample, in some embodiments, the flexible container 300 can collapsesuch that a distance between adjacent portions and/or components of thebulk material is reduced. As shown in FIG. 6C, the flexible container364 in the collapsed configuration can have a height H′ less than theheight H of the flexible container 364 in the expanded configuration. Inother embodiments any dimension of the flexible container 364 (e.g., thewidth W and/or the length L) can be decreased when the flexiblecontainer 364 moves from the expanded configuration to the collapsedconfiguration. In this manner, the movement of specific portions (e.g.,particles, pellets, grains, chunks, portions, and/or the like) of thebulk material is reduced relative to adjacent portions of the bulkmaterial. Similarly stated, when the flexible container 300, 364 ismoved from the expanded configuration to the collapsed configuration,the bulk material therein can be moved from a flowable (or partiallyflowable) state to a substantially non-flowable state. Thus, thepotential of load shifting of the bulk material within the flexiblecontainer 300, 364 is reduced and/or eliminated. Accordingly, theflexible container 300, 364 can be strapped and/or anchored within ashipping container using tethers, magnets and/or straps. Furthermore, asdescribed above with reference to FIG. 8, the bulkhead 325 includes thesleeve 321 and the shock absorbing member. In this manner the sleeve 321and the shock absorbing member (e.g., a steel member, series of membersor bumper) can be configured to absorb a portion of a force (e.g., loadshifting of the substantially solid mass within the rigid container) toreduce damage done to the rigid container, the flexible container 300and/or the bulk material. Similarly, as shown in FIG. 13, a bottomsurface of the flexible container 300 includes a sleeve 321.Furthermore, while shown in FIGS. 8 and 13 as being disposed in specificlocations, in some embodiments, a flexible container can include anynumber of sleeves 321 that can be disposed at any suitable location onor about the flexible container.

Any of the flexible containers described herein can be disposed and/orcoupled within a commercially-available, rigid shipping container. Inthis manner, processed or raw coal or other granular or powderedmaterial may be transported in a sealed container of a size and weightthat is within the capabilities of existing shipping and transferequipment utilized in connection with containerized transport.Currently, this is in the range of 25-30 tons per one twenty-footequivalent (TEU) container, which measures 20 feet by 10 feet by 8 feet,and approximately the same tonnage per two TEU containers, whichmeasures 40 feet by 10 feet by 8 feet. Using containerized transport, a5,000 TEU vessel can transport 100,000 tons of raw coal per voyage,which is substantially larger than the amount of raw coal per voyagethat can be transported using the Handy or Panamax class. If greaterquantities are desired, a 10,000 TEU vessel can be utilized, which cantransport approximately 240,000 tons of coal, or a 15,000 TEU vessel canbe used to transport in excess of 300,000 tons of coal.

In some embodiments, the flexible containers can be pre-loaded intorigid containers that are configured/dimensioned to be loaded intostandard shipping containers. In some embodiments, the flexiblecontainers can be arranged into pre-loaded stacks that are configured tobe placed into TEU containers.

In some embodiments, any of the flexible containers described herein(e.g. the flexible container 300) can be loaded and/or processed by adevice configured to compress, shape and/or prepare the flexiblecontainer for disposition within a rigid container (e.g., any of thecontainers of the types shown herein). For example, FIG. 14 is aschematic diagram of a form or device 1300 for shaping flexiblecontainers prior to placement within a rigid shipping container. Theform 1300 can have one or more moveable members. As shown, the form 1300has two pairs of moveable members 1340, 1350. The form 1300 can beoperable to control the size and/or shape of a flexible container whilethe flexible container is moving from an expanded configuration(indicated by the dashed lines identified as 1310) to a collapsedconfiguration (indicated by the solid lines identified as 1320). In someembodiments, moving the flexible container from the expandedconfiguration 1310 to a collapsed configuration 1320 without the form1300 can result in the collapsed configuration 1320 having an irregularshape, such as bowed sides, that can be difficult to stack and/orposition within a rigid container for shipping. The form 1300 can applyforce to the flexible container, such that gas is purged from theflexible container, the flexible container assumes a regular shape, andthe like when the flexible container in the collapsed configuration1320. The moveable members 1340, 1350 can be driven by a hydraulic pump,electric motor, internal combustion engine, and/or any other suitablemeans to apply a force to the flexible container. In other embodiments,the moveable members 1340, 1350 can be inflatable.

In some embodiments, the form 1300 can include a vibratory shaker whichcan aid the moveable members 1340, 1350 in shaping the flexiblecontainer while it is moving from the expanded configuration 1310 to thecollapsed configuration 1320. A vibratory shaker can act to fluidize thebulk material to increase its flowability and/or deformability while themoveable members 1340, 1350 apply a force to transition the flexiblecontainer from an expanded configuration to a collapsed configuration.

The pressure inside the flexible container can be reduced while themoveable members 1340, 1350 compact the flexible container. In someembodiments, the flexible container in the collapsed configuration 1320can assume a relatively rigid form with relatively flat side walls. Forexample, in embodiments where the internal volume of the flexiblecontainer includes a bulk flowable granular material, the collapsedconfiguration 1310 can include approximately no headspace to allow aportion of bulk material to move relative to another portion of the bulkmaterial. The form 1300 can be operable to urge the flexible containerto assume a collapsed configuration with a flat bottom, top, and/orsides, which can be conducive to stacking and/or loading the flexiblecontainer within a rigid shipping container.

The moveable members 1340, 1350 can retract once the flexible containeris in the collapsed configuration 1320, which can allow the flexiblecontainer to be removed from the form. The flexible container in thecollapsed configuration 1320 can retain the shape of the form 1300 afterbeing removed. Thus, in some embodiments, flexible containers can befilled and moved into a collapsed configuration 1320, and then stackedand/or staged for later shipment. In such an embodiment, the flexiblecontainers in the collapsed configuration 1320 can be loaded into arigid shipping container.

Although two pairs of moveable members 1340, 1350 operable to compactthe length and width of the flexible container are shown in FIG. 14, inother embodiments the form 1300 can include any number of moveablemembers. For example, a single moveable member can be operable tocompact the flexible container by applying a force to one side of theflexible container while, for example, the bottom and three other sidesare stationary. In another embodiment, the form 1300 can include sixmovable members, operable to compact the flexible container in threeorthogonal dimensions.

The most common sizes for rigid shipping containers are 20 feet or 40feet in length. In some embodiments, for example, in use with a flexiblecontainer, a 20-foot container can have the capacity of holdingapproximately 25-30 tons of raw granular coal or powdered coal. In someembodiments, to accommodate larger quantities of processed materials(such as 40-45 tons of pulverized material) a rigid container can bereinforced and/or specially designed to maximize the efficiency oftransporting coal.

As shown in FIG. 15, a typical rigid container 465 includes four cornerposts 466, 467, 468, 469. The rigid container 465 also includes longrails 470, 471, 472, 473 along of the top and bottom of the rigidcontainer 465, which are connected to the corner posts. The rigidcontainer 465 also includes short rails 474, 475, 476, 477 along the topand bottom of the rigid container 465, which are also connected to thecorner posts 466, 467, 468, 469. The corner posts, long rails and shortrails provide structural support for the rigid container 465, and enableit to be secured to a crane, or a truck or rail car. The rigid container465 also includes side panels 478, 479, 480, 481, bottom panel 482 andtop panel 483, which are secured to the corner posts, long rails andshort rails. In some embodiments, for example as seen in FIG. 15, therigid container 465 includes a hinged or sliding door 484 in the toppanel 483. The door permits loading and unloading of the material to betransported.

After processing, the granulated or powdered coal is loaded into therigid container 465. In some embodiments, system can include a flexiblecontainer (such as the flexible container 300) disposed within the rigidcontainer 465, and the coal can be loaded in via a front opening (e.g.,opening 313), as described above. The coal can be loaded into the rigidcontainer 465 and/or a flexible container therein with aconventional-type conveyor loading system, or feeding through anenclosed piping system, such as a forced-air fluid bed system or ascrew-based system. In other embodiments, the coal can be loaded intothe rigid container 465 and/or a flexible container by conventionalmechanical means, such as via a construction payloader. In yet otherembodiments, the coal can be loaded into the rigid container 465 and/ora flexible container by an air-driven system. As shown in FIG. 16, insome embodiments, a rigid container 565 can include a flexible pipe 586coupled thereto to facilitate a method using an air driven system.

During loading, the rigid container 465 may also be positioned above theground, at ground level or below ground. It could also be positioned onan automated track system such that multiple rigid containers can befilled in a continuous manner. Filling can be completed until the rigidcontainer 465 capacity is reached, as determined by volume or by weight.In other embodiments, as described herein, the rigid container 465and/or the flexible container therein (e.g., flexible container 300) canbe filled to a capacity that is less than the interior volume when theflexible container is in the expanded configuration.

As shown in FIG. 15, in one embodiment, coal is loaded through asealable opening in the top of the rigid container. This can include oneor more chutes positioned to receive the bulk material (e.g., raw coaland/or pulverized coal). The hinged or sliding door 484, or another typeof portal, on the top of the rigid container 465 permits access tointerior for loading. In such embodiments, a system can also include aflexible container, similar to the flexible container 300, having anopening in the top portion, rather than in the front portion (as shownin FIGS. 6A and 7). In the alternative, the entire top wall, or aportion of the top wall 483 of the rigid container 465 could be hingedto a side of the rigid container 465. Likewise, loading may beaccomplished through a sliding or hinged door 484, or another portal,positioned in the side of the rigid container 465. An entire side-wall,or a portion of a side-wall, could also be hinged to another side-wall,or to the remaining portion of the side-wall that provides access. Afterthe coal is loaded, the rigid container may be closed, locked and sealedfrom the outside air.

The rigid container 465 design can be such that the interior can besealed from outside air after the powder or granulated material isloaded therein. This may be accomplished by use of a permanent orextractable flexible container, such as the flexible container 300, apermanent or extractable hard liner, a single use throwaway recyclableliner or a purpose-built rigid container.

The liner and/or flexible container, whether permanent or single use,extractable, flexible or hard, can be manufactured of a punctureresistant, sealable material that does not interact chemically with theprocessed coal. The liner and/or flexible container disposed and/orcoupled within the rigid container 465 can be constructed from any ofthe materials described herein. An extractable liner will enable reuseof general purpose shipping rigid containers in the transport of otherproducts (avoiding rigid container dead-heading). If the material isdurable enough, an extractable liner would also permit efficient reuseof the liner for additional coal transport.

In some embodiments, a system can include a flexible container, of thetypes shown and described herein, disposed within a rigid container. Forexample, a flexible polymer-based bag with a thickness in the range of0.5 inches to 0.75 inches would be well-suited for use in lining therigid containers. The bag (or flexible container, such as the container300) can be made of a non-reactive material, such as plastic, vinyl orsilicon. The bag (or flexible container, such as the container 300 orthe container 364) could also be made of an environmentally friendlymaterial, or any material that is non-reactive, can be sealed, and willmaintain a vacuum. The purpose of the liner is to aid sealing thecontents of the rigid container, and to permit the rigid container to bereused for shipping of other goods after the coal is removed.

As shown in FIG. 15, the system includes a flexible container 400disposed within the rigid container 465. The flexible container 400,which can be similar to the flexible container 300, may be temporarilyheld in position within the rigid container 465 prior to filing throughthe use of hook and loop fasteners 485 positioned along the edges andcorners of the interior of the rigid container and the exterior of theliner. In some embodiments, the weight of the rigid container coal actsas a pressure seal when the bottom of the bag employs a flap forevacuating the coal.

As an alternative to a reusable flexible bag, in some embodiments, aliner may include a single-use sealable bag that may be discarded afteruse and recycled.

As an alternative to a flexible container, liner or bag, the rigidcontainer can be lined with a non-reactive coating, such as a ceramicmaterial. The coating might be permanent, in which case it could becleaned after use, such that the rigid container can be re-used forshipment of other goods and services. In the alternative, the coatingmight be applied to a temporary sheath that could be removed from therigid container and reused, permitting the rigid container to be usedfor other purposes.

Another approach is to have collapsible boxes (box within a box), withsealed hinges allowing for size to be minimized. The hinged box would beinserted into the outer rigid container by means of a sliding track orother method. The walls would be opened from their collapsed state andlocked, creating a sealable box. Another alternative approach would be apurpose built rigid container, with the interiors being ceramic orpolymer coated. Such coatings would permit efficient cleaning after coaltransport. A purpose-built rigid container could also be designed sothat it is collapsible in order to minimize cost of transport back toits point of origin.

Once sealed, air can be removed from the rigid container to reduce therisk of combustion, to minimize shifting of the bulk material therein orthe like. For example as shown in FIGS. 19 and 20 a rigid container 865can include a flexible container 800, a hose assembly 892, and a valveassembly 895. In some embodiments, air can be removed from the flexiblecontainer 800 with the valve assembly 895 positioned through one or moreof the side-walls or the top of the rigid container. The valve assembly895 can be positioned inside the rigid container such that the port isflush with the surface of the rigid container 896, so that it is notdamaged during loading, transport or unloading of the rigid container.The valve assembly can include a portal 897 that can be attached to anegative pressure (vacuum) source, and a valve mechanism 898 for openingand sealing the portal. Suitable value mechanisms can include a ballvalve, a butterfly valve, a gate valve or a globe valve. Alternativevalve mechanisms, including mechanisms that are automatically actuatedwhen a suitable negative pressure is achieved, may be utilized. Thevalve mechanism may also include a screen or filtration mechanism toprevent the rigid container contents from being drawn into the vacuumsystem. The vacuum could also be applied through multiple openings andseal assemblies on the upper and lower surfaces of the rigid container,or through the flexible pipe 586 (see e.g., FIG. 16) that is used tofill the rigid container. In some embodiments, the valve assembly 895can be fluidically coupled to the vacuum port (e.g., port 361) of aflexible container (e.g., container 300) disposed within the rigidcontainer.

Although shown as being coupled to the hose assembly 892, in otherembodiments, the valve assembly 895 or any other suitable valve for theingress (e.g., of the bulk material) and/or egress (e.g., of air) can becoupled directly to the flexible container. For example, in someembodiments, any suitable valve can be chemically welded to a side wallof a flexible container.

Regardless of the means for applying a vacuum, there can becorresponding openings in the liner or coating. With a permanentcoating, this could be accomplished by sealing the coating around thevacuum port. With a flexible or hard liner, a portion of the liner couldbe fitted around the portal in a configuration that seals the liner tothe surface adjacent the portal, such that when loaded with coal, aircannot leak into the liner. The liner could also include a region thatis permeable to gasses but not solid materials, such that air can bewithdrawn without coal powder and other solid materials being removedfrom the rigid container. After the vacuum is applied, to the portal,the portal opening is sealed to maintain negative pressure.

Vacuum sealing will minimize loss of volatiles from the coal. Further,the absence of oxygen will inhibit the combustibility of the processedcoal inside the rigid container. A vacuum pump system would be presentat loading and unloading sites. In one embodiment, a mobile vacuum pumpcan be utilized to extract the air from rigid containers are they arefilled in an automated process. In the alternative, the mobile vacuumpump can be equipped to seal multiple rigid containers at the same time.

If further protection from combustion is required, an inert ornon-combustible gas or mixture of gases may be injected into the rigidcontainer after it is filled with coal. The gas can be injected into therigid container through the vacuum port, or through a second portspecifically designed for injection of the gas.

Preferred gases include helium, neon, argon, krypton, xenon, and radon.Other gases and mixtures of gases can be used, as long as they displaceoxygen and provide a means of controlling the combustibility of thematerial in the rigid container. For example, nitrogen or carbon dioxidecould be used when transporting coal.

For unloading, the rigid container may include an outlet port that canbe attached to a hose and vacuum system at the end user location. Inanother embodiment, the rigid container can include a hinged or slidingdoor on the bottom panel as depicted in FIG. 17. In this configuration,the bottom door 687 is designed to withstand the weight of coal in theloaded rigid container. It is also designed to be opened via a handle orlatch 688 positioned along a side wall at the bottom of the rigidcontainer.

FIG. 21 is a view of a rigid container 965 showing a sliding hatch witha releasing mechanism controlled by an electrically activated sensor.The rigid container 965 can include, for example, tracks for slidinghatches. In some embodiments, a rigid container can include an automatictrip switch sensor to release or lock a sliding hatch. In someembodiments, a container can include a tracking sensor to identifywhether the container is fully loaded/fully unloaded.

FIG. 22 is a view of a rigid container 965 showing a top or bottom (orside) loading and unloading device by means of a flexible tube 992(allowing even distribution of materials during the loading process).The loading and unloading mechanism includes a locking collar that canbe coupled to the loading and unloading chute. The loading and unloadingmechanism includes a sealing valve for either the exhaust of air or theintroduction of inert gas.

In some embodiments, any of the containers shown and described hereincan include a grounding mechanism for electrically grounding thecontainer during the loading and/or unloading process, as well as duringtransportation. For example, in some embodiments, the flexible tube 992can include a ground wire or rod coupled thereto. The ground wire can,for example, extend from an area outside of the rigid container 965 intoan interior volume defined by the rigid container 965, an inner linerand/or a flexible container disposed therein. In this manner, the staticcharge that can develop from the contact between particles duringloading (or unloading) can be dissipated. More particularly, such staticbuildup can become hazardous when the materials contain, or are composedof, dust or powders (as are common with coal, ores, grain, aggregatesand other bulk materials to be handled by the systems and methodsdescribed herein). In addition the ground wire or rod, in thoseembodiments in which the flexible container is evacuated, the evacuationreduces friction during transport and thus minimizes the formation ofstatic charges during transport.

In some embodiments, the innermost layer of any of the containers shownand described herein is constructed of an anti static material, such ashigh density polyethylene, Acetal and Ester based ThermoplasticPolyurethane, amongst others. The material used on the inner layer ofthe liner bag can be any suitable material, generally composed ofmodified conductive thermoplastic compounds that allow for the rapiddissipation of static charge so that a significant electrostaticdischarge event does not take place during, loading, unloading and/ortransportation.

As shown in FIG. 18, the interior of the rigid container can include ahopper shaped bottom 790, 791 which directs material be removed from therigid container towards a portal positioned in the middle of the bottom.In this embodiment, the contents will flow from the rigid containeropening. Content removal can also be assisted with a pump and hoseassembly 792 or other device designed to disgorge the contents underpressure.

Unloading can also be accomplished via a portal or door on a side panel.If necessary, for unloading, one side of the rigid container could belifted or tipped up, or the rigid container could be positioned above anunloading chute so that coal or other materials can be extracteddirectly into a feeding or storage mechanism utilized by the end user. Adesign including a side portal or door is preferred, as the same portalor door could be used for loading and unloading of the coal or othervolatile material.

The liner also includes a release mechanism associated with the outletport or door. For example, the liner can include a breakaway region, afolded flap that may be unfolded for discharge of the contents, or arelease cord that opens the liner in a specific region. In suchembodiments, the liner mechanism can be positioned to align with therigid container discharge opening or mechanism.

In some embodiments, a collapsible bag, such as the flexible container300 or the flexible container 364, is utilized as the liner. In suchembodiments a sealable flap or a puncturable area can be opened when therigid container is opened, such as with a sliding or hinged door. In thealternative, the bag could have a portal or series of portals alignedwith the rigid container openings. These portals could also be attachedto an external hose, such that, when connected to the hose, the contentsof the bag could be removed.

An alternative embodiment entails a connection between the bag and theinterior or exterior of the rigid container, which could assist inremoval of the contents.

In some embodiments, the rigid containerization of powdered, granulatedor other processed coal, or raw coal, is such that large-scale rigidcontainerized transport ships can efficiently and safely transport thematerial to multiple end-users in multiple destinations. This allows for“on demand” transport of commodities to higher value markets and/orflexible distribution decision strategies for trading companies. Someembodiments can also be used for transport of other volatile andnon-volatile materials in powdered, granular and/or other solid forms.

Although certain embodiments are shown and described as being used tocontain raw coal, any of the embodiments herein can be used to containprocessed coal and/or other bulk materials. For example, in someembodiments, a method includes processing coal or other products intovalue added material at the location where it is mined, or anotherlocation, before being loaded onto ships for transport to end users. Theprocessed coal can then be loaded into a sealed, non-combustible rigidcontainer, for environmentally safe transport by land or sea. The sealedrigid containers can also store the coal (or other processed materials)such that the contents are not exposed to wind and rain, preventingproduct deterioration, product loss, and dispersion of potentiallyharmful dust and other materials into the air or land through leachingor exposure to the elements. By processing coal before shipping, andtransporting processed coal in sealed shipping containers, differentcoal products can be distributed to multiple users in differentlocations with relative ease. Thus, coal can be marketed and supplied ina much wider variety of formats than are currently available.

In this manner, the methods and systems described herein allow for thetrade in Lingnite Coal. Lignite coal has a very high moisture contentcausing its energy content (BTU per pound) to be relatively low whencompared with other types of coal (e.g., Bituminous, Sub-Bituminous andAnthracite). Thus, it is not practical to transport Lignite coal (eithernationally or internationally) using known methods. As a result, sitescontaining Lignite deposits generally have electrical generating orconcrete manufacturing plants constructed thereon. According to themethods described herein, Lignite coal can be processed at the mine toremove the moisture and pulverize the coal, thereby producing aprocessed coal having a higher energy content than some known forms ofcoal. Using the systems and methods described herein, the processedLignite coal can be economically packaged, handled and shipped.

Refined bulk materials such as Direct Reduced Iron (DRI) are extremelyreactive, corrosive and flammable. These products must be transported inspecially constructed rail cars, trucks and bulk ships. DRI is highlysusceptible to re-oxidation, overheating, and the generation of highlycombustible/explosive hydrogen if left unprotected. DRI reacts easilywith water, particularly seawater and produces heat if exposed toseawater or moisture laden sea air.

The flexible containers described herein are configured to eliminate orsignificantly reduce exposure to water and air thus eliminating orsignificantly reducing the possibility of combustion. An additionalprotection against combustion would be to insert an inert gas into thebag after sealing. Bulk ships generally avoid shipping DRI when possibleowing to the extremely corrosive nature of the material. The systems andmethods described herein eliminate the corrosive impact of DRI and othermaterials on the interior and exterior of bulk ships.

Although certain embodiments are shown and described as being used tocontain coal, any of the embodiments herein can be used to containand/or transport any suitable bulk materials. Such bulk materials caninclude, for example, the following ores: Argentite, Azurite, Barite,Bauxite, Bornite, Calcite, Cassiterite, Chalcocite, Chalcopyrite,Chromite, Cinnabar, Cobaltite, Columbite-Tantalite or Coltan, Cuprite,Dolomite, Feldspar, Galena, Gold, Gypsum, Hematite, Ilmenite, Magnetite,Malachite, Molybdenite, Pentlandite, Pyrolusite, Scheelite, Sphalerite,Talc, Uraninite, Wolframite. In other embodiments, such bulk materialscan include grains (either raw or processed). Grains that can bepackaged and transported according to the methods described hereininclude corn, wheat, soybean, oats or the like. Moreover, processedgrain products, such as flour, can also be packaged and transportedaccording to the methods described herein.

Any of the systems and containers described herein can be loaded andunloaded onto containerized ships, using conventional container loadingand transportation equipment. The loading and unloading of bulkmaterials according to the systems and methods described herein avoidsthe cost and/or hazards associated with bulk shipping and storage ofvolatile materials, and reduces the amount of product lost in theenvironment. Shipment of materials according to the systems and methodsdescribed herein also permits the transport of materials through largervessels, capable of transporting larger quantities of coal than bulkcarriers. Thus, containerized shipping can decrease transportation costsassociated with known methods of coal shipment.

Furthermore, some embodiments provide for control over the weight and/ordensity of the coal pile. By limiting the weight and/or density of thecoal pile, and by providing a non-reactive surface and a controlledatmosphere, the risk of spontaneous combustion can be minimized.Further, the risk of a chemical reaction between the coal and thecontainment vessel is minimized.

Transport of containerized coal according to the systems and methodsdescribed herein is environmentally safe when compared to known bulktransport methods, since the coal is not repeatedly exposed to the airand weather, and the creation and release of coal dust is minimized. Inaddition, embodiments described herein also serve to reduce inefficiencyin the trade imbalance. The imbalance in trade between various countriesand regions, more particularly between Asia and the United States, andmost particularly between China and the Unites States has for many yearsresulted in a surplus of containers in the United States. In particular,there remains significant unused container ship capacity from theeconomic crises of 2008 crash. Moreover, slowing manufacturing andexports from the U.S. have created an excess of shipping containers inthe U.S. By streamlining the transportation process, and using retrofitsystems for sealing existing used cargo containers, embodimentsdescribed herein will provide a means of returning cargo containers toAsia, including China, reducing the number of unused containers in theU.S. Some embodiments also provide a means for re-using containers inthe transport of other goods to the United States. Thus, rather thanusing containers one time, or shipping empty containers back to Asia forre-use, some embodiments enable reuse of containers back and forthbetween the U.S. and Asia.

FIG. 23A is a flowchart illustrating a method 1000 for storing and/ortransporting a bulk material, according to an embodiment. In someembodiments, the bulk material is stored and/or transported in aflexible container such as, for example, any of the flexible containersdescribed herein. In such embodiments, the flexible container caninclude a container body and a cover and can be configured to movebetween an expanded configuration and a collapsed configuration. Theflexible container further includes a side wall and defines an interiorvolume within the container body. In some embodiments, the side wall caninclude a substantially non-circular opening configured to receive abulk material. In some embodiments, the flexible container issubstantially similar to the flexible container 300 described hereinwith reference to FIGS. 6A and 7-13 or the flexible container 364described herein with reference to FIGS. 6B and 6C. While not explicitlydescribed, the flexible container can include any features included inthe flexible container 300 and or any other embodiment described herein.

In some embodiments, the method 1000 optionally includes aligning adelivery member with the opening defined by the side wall of theflexible container, at 1002. The delivery member can be any suitablemember. For example, in some embodiments, the delivery member is aconveyer. In some embodiments, a portion of the delivery member isdisposed through the opening defined by the side wall and is disposedwithin the interior volume of the container body, at 1004. In someembodiments, the method 1000 can include conveying a gas from a volumeoutside the flexible container to maintain the container in the expandedconfiguration. In some embodiments, the gas can be an inert gas. Inother embodiments, the gas can be air. In some embodiments, theinflation fluid can be conveyed into the flexible container via the sameopening through which the bulk material is conveyed.

The method includes conveying the bulk material into the flexiblecontainer via an opening therein, at 1006. In some embodiments, thedelivery member can be disposed within the interior volume such that atleast a portion of the delivery member is disposed at a rear portion ofthe interior volume. In this manner, the delivery member can transferthe bulk material through the opening and into the rear portion of theinterior volume of the container body. While transferring the bulkmaterial into the interior volume of the container body, in someembodiments, the delivery member can be configured to telescope suchthat a length of the delivery member disposed within the interior volumeis reduced. Similarly stated, the delivery member can retract at a givenrate through the opening. Thus, the bulk material (e.g., processed coal)can be loaded in a rear to front manner. Said another way, thetelescopic motion of the delivery member toward the opening isconfigured to even distribute the bulk material within the interiorvolume. In some embodiments, the method 1000 includes filling theinterior volume with the bulk material to a predetermined volume and/orweight. For example, in some embodiments, the method 1000 includesfilling the flexible container until the flexible container isapproximately 60 percent full (by volume when compared to the volume ofthe flexible container in the expanded configuration). In otherembodiments, the flexible container can be filled to any suitable level.For example, in some embodiments, the flexible container can be filledto a volume ratio of approximately 50 percent, 55 percent, 65 percent,75 percent, 85 percent, or more.

With the desired amount of bulk material transferred to the interiorvolume of the flexible container, the delivery member can be retractedthrough the opening defined by the side wall. With the delivery memberretracted, the cover included in the flexible container can be disposedabout the opening and coupled to the side wall, at 1008. For example, insome embodiments the cover can be coupled to the side wall via anadhesive strip. In other embodiments, the cover can be coupled to theflexible container in any suitable manner. In some embodiments, thecoupling of the cover to the side wall places the interior volume influidic isolation with a volume outside the flexible container.Similarly stated, the cover can be coupled to the side wall to define ahermetic seal.

With the cover coupled to the side wall and disposed about the openingthe pressure within the interior volume can be reduced, thereby movingthe flexible container from the expanded configuration to the collapsedconfiguration, at 1010. More specifically, container body and the covercan be placed in the collapsed configuration by evacuating a gas withinthe interior volume via a port. In some embodiments, the cover definesthe port. In other embodiments, the container body or the side wall candefine the port. In this manner, the port can be engaged by, forexample, a vacuum source such that the pressure within the interiorvolume of the container body is reduced. The reduction of the pressurewithin the interior volume can be such that container body deforms.Similarly stated, the vacuum source can exert a suction force on theinterior volume thereby urging at least a portion of the container bodyto deform under the force. Furthermore, the vacuum source can beconfigured to expose interior volume to the suction force such that theinterior volume is substantially devoid of a gas (e.g., air). Saidanother way, the interior volume is exposed to a negative pressure andthereby urges the container body to substantially conform to a contourof the bulk material disposed therein.

In some embodiments, the flexible container can collapse (e.g., conformto the bulk material) such that the bulk material disposed within thecontainer body can act as a substantially solid mass. For example, insome embodiments, the flexible container can collapse such that adistance between adjacent portions and/or constituents of a bulkmaterial is reduced. In this manner, the movement of specific parts(e.g., particles, pellets, grains, chunks, portions, and/or the like) ofthe bulk material is reduced relative to adjacent parts of the bulkmaterial. Thus, the potential of load shifting within the flexiblecontainer is reduced. In some embodiments, the substantial evacuation ofthe gas (e.g., air) within the flexible container can reduce the risk ofspontaneous combustion of the bulk material (e.g., coal).

FIG. 23B is a flowchart illustrating a method 3000 for storing and/ortransporting a bulk material, according to an embodiment. In someembodiments, the flexible container is substantially similar to theflexible containers 300, 364 described herein with reference to FIGS.6A-6C and 7-13. While not explicitly described in the context of themethod below, the flexible container can include any features includedin the flexible container 300, 364 and or any other embodiment describedherein.

The flexible container can be magnetically coupled to a rigid containerto define an interior volume within the flexible container, at 3002. Forexample, as shown in FIG. 6B, the flexible container can include magnetsoperable to magnetically attach to a rigid shipping container of thetypes shown and described herein. Thus, the flexible container can bemagnetically coupled to a rigid structure outside of the interior volumeof the flexible container. The magnets can be operable to couple a top,a side wall, a font, a rear, and/or any other portion of the flexiblecontainer to the rigid container. In some embodiments, the magneticcoupling between the flexible container and the rigid container can beoperable to maintain the flexible container in an expandedconfiguration, at 3004. In addition or alternatively, a gas canoptionally be conveyed into the interior volume to maintain the flexiblecontainer in the expanded configuration.

A bulk material is conveyed into the flexible container, at 3006.Conveying the bulk material, at 3006, can be similar to conveying thebulk material, at 1006, as shown and described with reference to FIG.23A. The pressure is reduced inside the flexible container such that apressure differential between the interior volume and a volume outsideof the interior volume is sufficient to overcome the magnetic coupling,at 3010 Similarly stated, reducing the pressure can result in theapplication of a force to the flexible container operable to overcomethe magnetic coupling force, such that the flexible container pulls awayfrom the rigid container. In this manner, the flexible container canmove from the expanded configuration towards the collapsed configurationas the magnets can become spaced apart from the rigid container.

Reducing the pressure inside the flexible container can move theflexible container from an expanded configuration to a collapsedconfiguration. When in the collapsed configuration, flowability of thebulk material can be impeded. Similarly stated, when in the collapsedconfiguration, the flexible container can be operable to impede themovement of a first portion of the bulk material with respect to asecond portion of the bulk material. The bulk material can form asubstantially solid block when the flexible container is in thecollapsed configuration.

In some embodiments, the magnets can be decoupled from the rigidcontainer before the pressure is reduced inside the flexible container.In such an embodiment, the magnets can be manually separated from therigid container. For example, tethers can be coupled to the flexiblecontainer which can be used to pull the flexible container and themagnets away from the rigid container. In embodiments, the magnets canbe electromagnets, which can be de-energized prior to reducing thepressure inside the flexible container.

FIG. 23C is a flowchart illustrating a method 4000 for storing and/ortransporting a bulk material, according to an embodiment. In someembodiments, the flexible container is substantially similar to theflexible container 300 and/or the flexible container 364 describedherein with reference to FIGS. 6A-6C and 7-13. While not explicitlydescribed, the flexible container can include any features included inthe flexible container 300 and or any other embodiment described herein.

The method includes maintaining the flexible container in an expandedconfiguration to define an interior volume, at 4004. Maintaining theflexible container in the expanded configuration, at 4004, can besimilar to maintaining the flexible container in the expandedconfiguration, at 1004, and/or 3004, as shown and described withreference to FIGS. 23A and 23B. For example, in some embodiments, theflexible container can be maintained in an expanded configuration bymagnetically coupling the bag to a frame or structure, by conveying agas into the flexible container, or the like. Bulk material can beconveyed into the flexible container, at 4006. The conveying the bulkmaterial, at 4006, can be performed via any suitable method, such asthose described herein (e.g., similar to conveying the bulk material, at1006, and/or 3006, as described above).

The flexible container can be shaped via a form into a desired sizeand/or shape, at 4009. The form can be similar to the form 1300, shownand described with reference to FIG. 14. In some embodiments, the formcan be coupled to the flexible container to maintain the flexiblecontainer in the expanded configuration, as described above. Moreover,as described above, the form can exert a force on the flexible containerto urge it to assume a particular shape.

The pressure can be reduced inside the flexible container, at 4010,which can be similar to reducing the pressure at 1010 and/or 3010. Insome embodiments, the actuation of the form can reduce the pressure bycompressing the flexible container. The flexible container, having beenshaped, at 4009, and moved into a collapsed configuration, at 4010, canbecome substantially rigid. The flexible containers can take andmaintain a shape amenable to stacking, storage and/or loading, such as acylinder and/or a rectangular prism with substantially flat surfaces. Inthis way, the flexible containers can be stored on site where the bulkmaterial is generated and/or prepared in anticipation of receivingshipping containers. Preparing bulk containers in advance of transportmeans (trains, trucks, barges, etc.) can advantageously decrease loadingtime as compared to filling shipping containers as they arrive.

Thus, in some embodiments, the flexible container can be optionallyremoved from the form and can be staged and/or stored for loading into ashipping container, at 4011. The flexible containers can be loaded intoa rigid shipping container, at 4012. In some embodiments, air bumperscan be inflated, at 4014, and/or other dunnage systems can be deployedto prevent the flexible container from shifting within the rigidcontainer.

FIG. 24 is a flowchart illustrating a method 1100 for processing coal atthe mine or railhead, at 1101. At either location, the coal can beprocessed into crushed, granulated or powder form, and graded by avariety of factors, such as quantity, type, size, moisture content, andash content. Processing can also entail mixing of different grades ofcoal (BTU content), in order to achieve specialized coal products forparticular end users.

Additionally, the processing can include coal washing and drying to meetenhanced end user specifications. At the time of processing, the coalcan be loaded into sealed containers 1102. The containers can be loadedaccording to any of the methods described herein. Moreover, thecontainer can be any of the containers described herein. After loading,the containers can be purged of air, and, if desired, filled with aninert or other gas that reduces the risk of combustion 1103. The filled,sealed, and oxygen purged containers can be stored for later transport,at 1104. Loaded, sealed containers may also be placed on trucks 1105,for delivery to a railhead 1107, where the containers are loadeddirectly onto railcars designed for transport of cargo containers. Inthe alternative, the containers may be loaded onto railcars 1105 fordirect transport to ports that handle containerized cargo 1110. At theport, the sealed containers can be stored 1115 until scheduled for seatransport, when they may be loaded onto mid- to large-sized containerships 1120.

After loading on a ship 1120, the containerized material is transportedvia sea 1125 to a destination port 1130, where the containers areunloaded 1135. Once unloaded, the containers can be stored for futuretransport 1140, or immediately loaded onto railcars or trucks 1145 fortransport to the end user 1150. Once the containers arrive at the enduser location they are unloaded form the transport means 1155, and maybe stored until needed 1160, or opened such that the contents are madeavailable for immediate use 1165.

In some embodiments, a shipping container for the transportation ofgranular materials includes a load-carrying space which is sealable toprevent ingress and egress of gas. In some embodiments, theload-carrying space is provided by a liner positioned within theshipping container. In some embodiments, the liner is removable from thecontainer. In some embodiments, the liner can be formed of a polymermaterial. In some embodiments, the liner is a flexible bag. In otherembodiments, the liner is a collapsible box. In still other embodiments,the liner is coated on the interior of the shipping container. In suchembodiments, the liner is formed of a material that is non-reactive withcoal. In some embodiments, the liner has a thickness in the range 1.27cm to 1.91 cm (0.5 to 0.75 inches).

In some embodiments, a shipping container includes a sealable loadingport for loading granular materials into the load-carrying space. Insome embodiments, the shipping container includes a port for extractinggasses from the load-carrying space, or injecting gasses into theload-carrying space. The port can be configured for connection to avacuum source for evacuation of gasses from the load-carrying space. Theport can be configured for connection to a source of inert gas forinjecting inert gas into the load-carrying space. In some embodiments,the shipping container is a twenty-foot equivalent container.

In some embodiments, a method of transporting granular material includesloading the granular material into a container. The method can furtherinclude sealing the load-carrying space and extracting gas from the loadcarrying space to reduce the pressure in the load-carrying space tosubstantially below atmospheric pressure. In some embodiments, themethod includes injecting an inert gas into the load-carrying space topurge air from the load-carrying space.

While embodiments herein have been described with reference to thetransportation of coal, other materials may be transported utilizing thesame systems and methods to obtain comparable advantages. For examplethe system and method may be suitable for transporting Potash. Potash isa mined and processed mineral used primarily as fertilizer. Unlike coal,potash is not combustible yet has specific chemical characteristics thathave significant transport and storage challenges. Embodiments describedherein effectively meets those issues and do so in a more efficientmanner than current methods and/or technologies.

Potash is commonly transported in crystalline form. These crystals areextremely sensitive to humidity and moisture, forming clumps and “pancaking” when exposed to humidity and moisture. Current transportrequires specialized rail cars and truck bodies that keep the potashfrom coming into contact with water. These specialized vehicles areexpensive and require considerable maintenance. Current storagefacilities, at the processing plant, at both sending and receiving portsand distribution centers are specialized and expensive to construct.Current handling methods and facilities at all the above steps arecostly to build and maintain. By applying the technology describedherein to potash, transport becomes more efficient, storage will notrequire expensive facilities, handling at ports and distribution centerswill be more efficient and cheaper and ocean transport will be scalable,more flexible, cheaper and much more efficient.

In some embodiments, the bulk material can be processed at or near themine. For example, processing may include milling to produce granular orpowdered coal of a specific size desired by an end user. Processing mayalso entail washing or chemical processing to remove undesirablematerials and gases, or drying to produce material with specified, knownwater content. Examples of pulverizing equipment that may be utilizedinclude mills such as the ball and tube mill or the bowl mill. Byprocessing the coal at the mine, at the rail-head or elsewhere in thesupply chain, the coal may be supplied in the exact form specified bythe end user, such that the coal need not be processed by the end userbefore it is consumed. For a power plant, this means that the suppliedcoal can be fed directly into the power generation furnace or boiler,avoiding the need for complex milling and drying equipment. Thus, theplant operator need not install, maintain or operate such equipment,significantly reducing operating costs and plant size. The plantoperator may also reduce environmental risks and issues, as coal may bestored in containers until needed, rather than in open piles. Ascontemplated herein, coal may be supplied in the following forms: rawlump, granulate, or powder, or mixed with higher or lower BTU coal toend user specifications.

While various embodiments have been described above, it should beunderstood that they have been presented by way of example only, and notlimitation. Where methods described above indicate certain eventsoccurring in certain order, the ordering of certain events may bemodified. Additionally, certain of the events may be performedconcurrently in a parallel process when possible, as well as performedsequentially as described above

For example, in reference to FIGS. 1-3, while the flexible container 100is shown as receiving the conveyer C, in other embodiments, a flexiblecontainer can receive any suitable delivery member. In otherembodiments, a container can include a portion of a delivery membertherein. For example, as shown in FIG. 25, a flexible container 2000includes a container body 2010 and a side wall 2012. The container body2010 defines an interior volume 2011 and is configured to house, atleast partially, an internal chute 2017. The side wall 2012 defines anopening 2013 configured to be aligned with the internal chute 2017.Furthermore, a delivery hose 2016 can be configured to couple to theside wall 2012 such that the delivery hose 2016 and the internal chute2017 are in fluid communication. In this manner, the delivery hose 2016can be configured to transfer, for example, a pulverized (e.g.,processed) coal. In addition, the internal chute 2017 can be configuredto telescope in the direction of the arrow AA (e.g., mechanically and/orelectrically) such that the processed coal is loaded into the flexiblecontainer 2000 from the rear forward. Thus, the weight distribution ofthe processed coal can be controlled.

Where schematics and/or embodiments described above indicate certaincomponents arranged in certain orientations/or positions, thearrangement of components may be modified. Similarly, where methodsand/or events described above indicate certain events and/or proceduresoccurring in certain order, the ordering of certain events and/orprocedures may be modified. While the embodiments have been particularlyshown and described, it will be understood that various changes in formand details may be made.

For example, although the flexible container 300 is shown and describedas including a bulkhead 325 that includes a sleeve 321 that receives ashock absorbing member, in other embodiments, the flexible container 300need not include a bulkhead 300. For example, in some embodiments, theflexible container 300 can be disposed and/or coupled within a rigidshipping container to form a shipping system that is devoid of a dunnagebag, bulwark, bulkhead and/or any other mechanism for absorbing a loadproduced by the movement of the bulk material within the flexiblecontainer 300. In particular, as described above, when the flexiblecontainer 300 is moved from the expanded configuration to the collapsedconfiguration, the bulk material therein can be moved from a flowable(or partially flowable) state to a substantially non-flowable state.Thus, the potential of load shifting of the bulk material within theflexible container 300 is reduced and/or eliminated. Accordingly, theflexible container 300 can be coupled within a rigid container solelywith a tether or strap (i.e., without the need for a bulwark, dunnagebag or the like).

Conversely, although the flexible container 300 is shown and describedas including a bulkhead 325 that is constructed separately from andlater attached to a container body, in other embodiments, a flexiblecontainer can include an integrated bulkhead, dunnage system or thelike. For example, in some embodiments, a flexible container can includean inflatable portion (e.g., towards the rear or front thereof)configured to be inflated in conjunction with loading the flexiblecontainer with the bulk material. In this manner, the flexible containercan provide additional protection to the rigid container within which itis disposed. Similarly stated, this arrangement can obviate the need forexternal dunnage bags, bulwark systems or the like.

FIGS. 26-29 depict flexible containers (which can be similar to theflexible container 300) with various configurations of buffer ribs. FIG.26 is a front view of a flexible container 4300 having buffer ribs 4382extending circumferentially around the flexible container. The bufferribs 4382 can be operable to resist movement of the flexible container4300 when it is disposed within a shipping container. For example, thebuffer ribs, 4382 can be inflated to take up excess space between theflexible container 4300 and the shipping container. FIG. 27 is similarlya front view of a flexible container 5300 with buffer ribs 5382 disposedon the edges of the flexible container, and FIG. 28 is a front view of aflexible container 6300 having buffer ribs 6382 disposed on the bottomof the flexible container. In other embodiments, buffer ribs can bedisposed on any surface, edge, corner, etc. of a flexible container.

Although various embodiments have been described as having particularfeatures and/or combinations of components, other embodiments arepossible having a combination of any features and/or components from anyof embodiments as discussed above. For example, any of the rigidcontainers described herein can include any of the flexible containersdescribed herein.

What is claimed is:
 1. A method, comprising: maintaining a flexiblecontainer in an expanded configuration to define an interior volume;conveying a bulk material into the interior volume of the flexiblecontainer via an opening defined by the flexible container; and movingthe flexible container from the expanded configuration to a collapsedconfiguration such that movement of a first portion of the bulk materialwithin the interior volume relative to a second portion of the bulkmaterial within the interior volume is limited.
 2. The method of claim1, wherein the maintaining includes conveying a gas from a volumeoutside the flexible container into the interior volume.
 3. The methodof claim 1, wherein: the maintaining includes removably coupling aportion of the flexible container to a rigid structure outside of theinterior volume; and the moving includes decoupling the portion of theflexible container from the rigid structure.
 4. The method of claim 1,wherein: a portion of the flexible container is in contact with a rigidstructure outside of the interior volume when the flexible container isin the expanded configuration; and the portion of the flexible containeris spaced apart from the rigid structure when the flexible container isin the collapsed configuration.
 5. The method of claim 1, wherein themoving includes reducing a pressure within the interior volume.
 6. Themethod of claim 1, wherein: the maintaining includes forming a magneticcoupling between a portion of the flexible container and a rigidstructure disposed outside of the interior volume; and the movingincludes reducing a pressure within the interior volume such that apressure differential between the interior volume and a volume outsideof the interior volume is sufficient to overcome the magnetic coupling.7. The method of claim 1, wherein: the flexible container has a firstportion and a second portion; the maintaining includes placing the firstportion of the flexible container into contact with a rigid structuredisposed outside of the interior volume; and the moving includesreducing a pressure within the interior volume such that the firstportion of the flexible container is spaced apart from the rigidstructure, the first portion configured to deform a first amount whenthe flexible container is moved from the expanded configuration to thecollapsed configuration, the second portion configured to deform asecond amount when the flexible container is moved from the expandedconfiguration to the collapsed configuration, the second amountdifferent than the first amount.
 8. The method of claim 1, wherein themoving the flexible container from the expanded configuration to thecollapsed configuration is performed such that the bulk material is in asubstantially non-flowable state.
 9. The method of claim 1, wherein thebulk material is at least one of a granular substance or a powderedsubstance, the bulk material forming a substantially solid block whenthe flexible container is in the collapsed configuration.
 10. A method,comprising: forming a magnetic coupling between a portion of a flexiblecontainer and a rigid shipping container to define an interior volumewithin the flexible container; conveying a bulk material into theinterior volume of the flexible container; and reducing a pressurewithin the interior volume such that a pressure differential between theinterior volume and a volume outside of the interior volume issufficient to overcome the magnetic coupling.
 11. The method of claim10, wherein the reducing the pressure includes moving the flexiblecontainer from and expanded configuration to a collapsed configuration,that movement of a first portion of the bulk material within theinterior volume relative to a second portion of the bulk material withinthe interior volume is limited when the flexible container is in thecollapsed configuration.
 12. The method of claim 11, wherein the bulkmaterial is at least one of a granular substance or a powderedsubstance, the bulk material forming a substantially solid block whenthe flexible container is in the collapsed configuration.
 13. The methodof claim 10, wherein the first portion of the flexible containerincludes a plurality of magnets.
 14. The method of claim 10, wherein thefirst portion of the flexible container defines a plurality of sleeves,each of the plurality of sleeves containing a magnet.
 15. The method ofclaim 10, further comprising: coupling the container within the rigidshipping container via a non-magnetic coupling.
 16. The method of claim10, further comprising: coupling the container within the rigid shippingcontainer via a tether, a first portion of the tether coupled to theflexible container, a second portion of the tether configured to becoupled to the rigid shipping container, a length of the tetherconfigured to change when the container body and the cover are movedfrom an expanded configuration to a collapsed configuration.
 17. Amethod, comprising: contacting a magnetic portion of a flexiblecontainer to a side wall of a rigid shipping container to define aninterior volume within the flexible container; conveying a bulk materialinto the interior volume of the flexible container; and moving theflexible container from an expanded configuration to a collapsedconfiguration such that the magnetic portion of the flexible containeris spaced apart from the side wall.
 18. The method of claim 17, whereinthe moving includes reducing a pressure within the interior volume suchthat a pressure differential between the interior volume and a volumeoutside of the interior volume is sufficient to move the magneticportion of the flexible container apart from the side wall.
 19. Themethod of claim 17, wherein the bulk material is a powdered substance,the powdered substance forming a substantially solid block as a resultof the moving.